The problem of labor shortages is one facing many developed countries, but in Japan – where over 65s now account for some 30% of the population – the problem is now particularly acute, with the nation said to be short of more than 600,000 workers. Technology offers one solution, and JBT is highlighting innovative, labor-saving systems at FOOMA 2022, Japan’s international food industry exhibition, which runs until June 10.
Visitors to the JBT booth in the Tokyo Big Sight exhibition center will have a chance to see how semi- and fully-automatic machines are helping Japanese protein processors cope with staff shortages, while helping improve both efficiency and hygiene.
Innovative portioning One such solution is the DSI Waterjet Portioning System, a precision machine for intense, high-accuracy cuts, which uses a next generation scanner for effortless all-in-one fat trimming, weight-based portioning, and nugget generation. Designed for high volume portioning, the DSI Waterjet Portioning System gives processors the ability to mix and match products and orders on any given day.
Optimizing efficiency Similarly, the Frigoscandia GYRoCOMPACT 70 Spiral Freezer, the latest in the best-selling range of GYRoCOMPACT freezers, features a 100% cleanable, open-profile self-stacking spiral design, including an improved FRIGoBELT® Nova for optimizing efficiency, capacity and layout flexibility.
The GYRoCOMPACT 70 also features significant environmental improvements, including an increased capacity of up to 20% over a smaller space and a reduction in oil consumption of as much as 75%.
For end-of-the-line packaging, JBT Proseal offers an extensive range of manual, semi-automatic and fully-automatic tray sealing machines with throughputs from 6 to 240 packs per minute. In addition, all tray sealing machines in Proseal’s range are capable of modified atmosphere packaging.
JBT will be exhibiting at FOOMA 2022 in Booth 6C-55, Hall 6 at Tokyo Big Site, Japan until June 10.
Rising demand for convenience food products, economic growth and shelf-life extension along with other factors are primary factors boosting the global frozen bread market. In fact, the market is experiencing consistently strong growth of around 4.3% every year. JBT’s range of hygenic, efficient spiral freezers are ideally placed to support such growth, particularly in growing markets such as Latin America.
Frozen bakery products are increasingly becoming an integral part of the daily diet around the world. Busy lifestyles have contributed to the growth of the bread manufacturing industry and an increasing emphasis on producing new products that can cater to the rise in demand from consumers. The increase in consumption of frozen bakery products is also being strongly echoed in the emerging markets of Asia Pacific and Latin America.
Like many other countries, Brazil is experiencing strong growth in frozen bakery products, whose worth is expected to exceed $26 billion in 2022, according to Caio Guillen, JBT’s Marketing Manager for South America.
JBT will be highlighting its entire portfolio focused on this segment at FIPAN 2022, Latin America’s largest bakery and confectionery trade exhibition, from 19-22 July in São Paulo’s Expo Center Norte.
Showcasing benefits Innovation in products and processes has been the main focus of the industry, which has sought even greater and broader professionalization, with investments in larger-scale production lines, with a high degree of automation and technology, guaranteeing products of the highest quality and food safety to the end consumer, says Fabio Viegas, Sales Manager at JBT in Brazil.
FIPAN 2022, an event which brings together some of the largest bakery processors in the country alongside other bakeries and confectioners, will provide JBT with an opportunity to showcase its complete portfolio of solutions dedicated to this segment. These include proofing, chilling, freezing, and baking systems designed to efficiently and reliably produce a variety of safe, attractive bakery and confectionery products.
Unrivalled savings One of the solutions that will be presented is the GYRoCOMPACT® Spiral Freezer Series, which offers state-of-the-art innovations in continuous freezing. Offered in different models, the GYRoCOMPACT can serve companies from large to small, delivering reliability, consistency, food safety, energy and space savings, quick installation and easy relocation, among other incomparable advantages.
The GYRoCOMPACT 60 delivers amazing energy savings compared with previous versions, including a 65% reduction in drive power usage. This version generally serves lines with a capacity of 2000 to 3000Kg/h.
The recently launched GYRoCOMPACT70 meanwhile features significant advances in food safety, performance and space optimization, including increased capacity of up to 20% on a smaller space, an enhanced hygienic design and a reduction in oil consumption of up to 75%. Generally offered for lines with a capacity from 3000 to 5000Kg/h.
For smaller bakers, the GYRoCOMPACT 40 – capable of freezing capacities of 1,000 kg per hour – is the most compact spiral freezer ever made, featuring unrivalled energy efficiency savings and an emphasis on hygiene by design.
JBT will be exhibiting at FIPAN 2022 at Expo Center Note, São Paulo, Brazil from July 19-22.
For fish and seafood processors, in common with customers across protein industries, rapidly rising gas prices have made apparently cheaper freezing options very costly. But how to beat the gas price-crisis while maintaining a product that’s superior in both quality and appearance?
Long-term gains Liquid Nitrogen prices in Europe have soared in 2021-22, with the increase putting pressure on companies using cryogenic – or gas-based – freezers.
“Although cryogenic freezers have a lower initial investment cost than mechanical freezers, there’s a high running cost for the gas, and this is especially true at the moment,” explains Martin Andersson, JBT’s Application Manager for Value Stream Spiral Freezers. “With a mechanical system like the ADVANTEC freezer, there is a bigger investment at the start, but companies reach a break-even point within a few years, at which point it becomes considerably cheaper.”
Smoother processing In the case of fish and other seafood, the freezing process itself is not without its challenges, and this is another area where the ADVANTEC offers a distinct advantage. “If you freeze thinner products like fish, you want them to come out without wrinkles,” says Andersson. “With our knowhow and experience we know how to get you the best product appearance.”
Andersson says the ADVANTEC can also be combined for effective glazing. “Almost all seafood is glazed; you need to put some water on it, so the surface doesn’t dry out,” he explains. Fish can quickly become rancid on just the surface but it spoils the product, so you want to glaze. We can assist the customers to find the right solutions and we can do tests for them in our lab to make sure they get the end results they want.”
Reliable solutions “At JBT, we have very reliable and hygienic freezing solutions that keep customers’ businesses running as they should,” Andersson adds. “If you choose the wrong freezer or process, you can end up with a poor or dry product quality. Whereas, with the ADVANTEC impingement freezer, you will get a juicier and fresher product.”
When it comes to freezing fruits, vegetables or even fish, pasta and rice, the problem of products sticking together into a homogenous mass can be all too common. But did you know that Individually Quick Frozen (IQF) technology from JBT’s Frigoscandia FLoFREEZE® can overcome these pitfalls and deliver improved product quality and yield?
Lars Michael Svensson, JBT Regional Sales Support Manager, here outlines some of the key advantages offered by the FLoFREEZE and provides tips on achieving consistently optimum performance.
One of the first advantages you have with the FLoFREEZE is its flexibility: you can quick-freeze a huge range of products with the same machine. For example, you can run small fish one day, pasta the next, rice the third and strawberries the fourth, and you can do all that with the same FLoFREEZE system.
At the same time and thanks to IQF innovations, the quality of the product coming out of the freezer is fantastic from all the customer feedback we have received. It is also a very efficient way of freezing products. By freezing fast, water loss is far lower, so you can achieve a very good yield. And thanks to its speed, the footprint of the FLoFREEZE is substantially smaller than a standard freezer system, which would need to be far larger to handle similar volumes.
Product quality is maintained thanks to gentle handling which allows delicate products such as berries, fresh spices and tropical fruits to be maintain their fresh appearance and flavor characteristics.
True fluidization So how does the FLoFREEZE work? IQF technology uses an airstream to freeze products one-by-one. This allows for the movement of air around each product to separate them, so they don’t stick together. The FLoFREEZE provides true fluidization, using a patented air flow system that separates and freezes the most delicate products, while simultaneously fulfilling the industry’s toughest requirements for hygiene, economy and user-friendly operation.
Products typically run through the FLoFREEZE are smaller dimension foods that can fluidize, such as fruits, berries, vegetables, pasta and shrimps. The products float in the airstream, behaving like a liquid, which allows us to individually freeze the surfaces, so they won’t stick together.
Optimizing freezing But how can customers get the most out of this technology? JBT offers a wealth of experience and knowhow that can be utilised to support customers in overcoming difficulties and finding the right solution for their specific products. With knowledge based on 60 years’ experience in IQF freezing and food processing, our food processing technologists will help guide and adapt processes according to customers’ production needs.
Effective solutions Both inside and entering the machine, we have options to separate products depending on shape, dimensions and temperature. A vibratory shaker feeds the product into the machine, so you get an even-flow. Then inside the machine, on the first IQF track – where we carry out crust freezing – customers have the option of running an agitation process, meaning the product is moved back and forth rapidly to separate it.
The FLoFREEZE allows you to restrict the amount of air at entrance, to pre-cool the product before fluidization begins. Further, we have options to control air coming through the product bed: instead of a constant flow, we have a pulsator which opens and closes fast to variate the airstream causing the product to move up and down.
Once it moves onto the second belt, the product is taken down to -18C. Thanks to the process carried out in the first stage, the product can move to this second belt without having risk of sticking together and creating lumps. So using all these options, we help customers get the most out of their FLoFREEZE and enable them to benefit fully from the system’s flexibility, speed and undoubted effectiveness.
What’s the best freezer option for a start-up? Cost-effective and compact are two words that would spring to mind, but also efficiency and Return on Investment. JBT’s Frigoscandia GYRoCOMPACT® 40 (GC40) self-stacking spiral freezer is the most compact, hygienic and efficient spiral freezer ever made, and crucially it’s a system that comes with all the same winning JBT features of a larger machine.
Of course when it comes to the initial investment, cryogenic freezing may at first appear tempting, but soaring energy prices have affected the production of liquid nitrogen worldwide, meaning an apparently cheaper option could turn out to be significantly more expensive. Perhaps this is one of the reasons the GC40 experienced a substantial sales increase in the second half of 2021 as customers sought more cost-effective alternatives.
Complete package But what is it that makes the GC40 special? Well, although small – as the name suggests – the GC40 is capable of freezing capacities of up to 1,000 kg/hour; a substantial amount for its size, explains JBT’s Director of Value Stream & Global Product Line for Spiral Freezers, Torbjörn Persson. “The GC40 is aimed at start-ups or companies moving from using cryogenics for freezing,” he says. “Energy has crept up in most parts of the world, and liquid nitrogen is now really expensive to produce and use.”
This is where the GC40 fits in: for smaller companies or companies converting from cryogenics, the GC40 is packaged in one piece, it’s relatively simple to set-up and has all the latest hygienic features expected from JBT. Extremely compact at only 6.5 meters long and 2.4 metres wide, the GC40 freezer can also be as low as 2.9 metres high (depending on required capacity).
“The GC40 is compact, very efficient and built to the latest standards, and even though it’s small, you still have the same features you would have on a larger machine, including Clean-In-Place (CIP),” continues Persson.
Higher capacity So what are some of the built-in benefits of the GC40? As well as unrivalled energy efficiency and freezer power consumption, the machine features the unique FRIGoBELT® Nova self-stacking belt that forms a closed freezing zone to eliminate the risk of products moving by horizontal airflow. Meanwhile the FRIGoDRIVE® system removes the need for a center drum with no supports or rails to cause jamming. Hygiene-by-design also takes priority in the GC40 with an open profile design to minimize dirt traps and the removal of stationary parts in the belt stack to enable simpler cleaning.
Crucially, the CG40 also features 35%-40% higher capacity than any similar competitor model. Small wonder then that the freezer saw a surge of sales in late 2021. “The GC40 was built to serve smaller processors, some who are just starting up and others who are converting from liquid hydrogen,” Persson adds. “We’ve seen some customers skipping the liquid nitrogen and going straight to mechanical.”